Two-layer multi-strand cords having very low, low and medium moduli

ABSTRACT

A two-layer multi-strand cord ( 60 ) comprises an internal layer (CI) of the cord made up of J&gt;1 internal strands (TI) and an external layer (CE) of the cord made up of L&gt;1 external strands (TE). The cord satisfies the relationship 100≤MC≤175, where MC=(J×MI+L×ME)/(J+L); MI=200×cos 4 (α)×[Q×(D 1 /2) 2 ×cos 4 (β)+N×(D 2 /2) 2 ×cos 4 (γ)]/[Q×(D 1 /2) 2 +N×(D 2 /2) 2 ]; and ME=200×cos 4 (α′)×[Q′×(D 1 ′/2) 2 ×cos 4 (β′)+N′×(D 2 ′/2) 2 ×cos 4 (γ′)]/[Q′×(D 1 ′/2) 2 +N′×(D 2 ′/2) 2 ], where D 1 , D 1 ′, D 2 , D 2 ′ are in mm, α and α′ are the helix angle of each internal and external strand (TI), β and β′ are the helix angle of each internal thread (F 1 , F 1 ′), and γ and γ′ are the helix angle of each external thread (F 2 , F 2 ′).

BACKGROUND

The invention relates to multi-strand cords that can be used notably for reinforcing tyres, particularly tyres for heavy industrial vehicles, and to tyres using such cords.

A tyre having a radial carcass reinforcement comprises a tread, two inextensible beads, two sidewalls connecting the beads to the tread and a belt, or crown reinforcement, arranged circumferentially between the carcass reinforcement and the tread. This crown reinforcement comprises several reinforcements having different functions.

The crown reinforcement generally comprises a working reinforcement comprising two working plies, or crossed plies, comprising filamentary metal working reinforcing elements arranged substantially parallel to one another within each working ply, but crossed from one ply to the other, that is to say inclined, symmetrically or asymmetrically, with respect to the median circumferential plane, by an angle generally ranging between 15° and 40°. This working reinforcement makes it possible, included amongst other functions, for the transverse loadings applied by the ground to be transmitted at least partially to the tyre when the latter is running, so as to provide the tyre with steering capability, namely to give the tyre the ability to allow the vehicle to which it is fitted to corner.

Such filamentary metal working elements are notably described in WO2008026271. WO2008026271 describes two-layer multi-strand cords comprising an internal layer of the cord made up of J>1 internal strands wound in a helix and an external layer of the cord made up of L>1 external strands wound around the internal layer of the cord. Each internal and external strand has multiple layers and comprises at least an internal layer made up of Q>1 internal threads, possibly an intermediate layer made up of P>1 intermediate threads wound around the internal layer, and an external layer made up of N>1 external threads wound around the internal or intermediate layer.

In WO2008026271, the objective is to provide filamentary working reinforcing elements that have a stiffness and a breaking strength that are as high as possible so as to avoid the damage caused to the crown reinforcement, and notably to the working reinforcement, by the obstacles encountered by the tyre when it is running.

In WO2008026271, this objective is achieved by increasing the number of internal strands and external strands as far as possible with respect to conventional multi-strand cords in which the breaking strength is lower and for which J=1 and L=6, such as notably described in WO2015090920. Thus, in WO2008026271, the objective is to combat the deformation imposed by the obstacles encountered by countering them with cords that are as stiff and mechanically strong as possible.

However, while this solution is effective against obstacles of relatively small or medium size, it proves ineffective with regard to larger-sized obstacles. Specifically, in such cases, the loadings exerted on the cords are higher than the hardness of the steel and the obstacle therefore shears through the cords, and the stiffer these cords are, and the better they oppose the deformation imposed by the obstacle, the more easily they become sheared.

One object of the invention is a cord that makes it possible to avoid the damage caused by obstacles that highly stress the crown reinforcement, notably the working reinforcement of the tyre.

SUMMARY

Cord According to the Invention

To this end, one subject of the invention is a two-layer multi-strand cord comprising:

-   -   an internal layer of the cord made up of J>1 internal strands         wound in a helix, each internal strand having two layers and         comprising:         -   an internal layer made up of Q≥1 internal threads of             diameter D1, and         -   an external layer made up of N>1 external threads of             diameter D2 wound around the internal layer,     -   an external layer of the cord made up of L>1 external strands         wound around the internal layer of the cord, each external         strand having two layers and comprising:         -   an internal layer made up of Q′≥1 internal threads of             diameter D1′,         -   an external layer made up of N′>1 external threads of             diameter D2′ wound around the internal layer,             the cord satisfying the following relationship:             100≤MC≤175             where             MC=(J×MI+L×ME)/(J+L) where             MI=200×cos⁴(α)×[Q×(D1/2)²×cos⁴(β)+N×(D2/2)²×cos⁴(γ)]/[Q×(D1/2)²             +N×(D2/2)²] where:

-   D1 and D2 are expressed in mm,

-   α is the helix angle of each internal strand in the internal layer     of the cord,

-   β is the helix angle of each internal thread in the internal layer     within each internal strand, and

-   γ is the helix angle of each external thread in the external layer     within each internal strand, and     ME=200×cos⁴(α′)×[Q′×(D1′/2)²×cos⁴(β′)+N′×(D2′/2)²×cos⁴(γ′)]/[Q′×(D1′/2)²     +N′×(D2′/2)²] where:

-   D1′ and D2′ are expressed in mm

-   α′ is the helix angle of each external strand in the external layer     of the cord,

-   β′ is the helix angle of each internal thread in the internal layer     within each external strand, and

-   γ′ is the helix angle of each external thread in the external layer     within each external strand.

Unlike in the prior art in which the cords have modulus values much higher than 160 GPa and are therefore relatively stiff, the inventors have found that the cords according to the invention, with lower modulus values, perform better against obstacles that highly stress the crown reinforcement of the tyre.

Specifically, the inventors have found that it was more effective to hug the obstacle by using a cord with a lower modulus than to attempt to stiffen and reinforce the cords as far as possible in order to oppose the deformations imposed by the obstacles as was taught in the prior art. By hugging the obstacles, the shearing imposed on the cords and therefore the risk of breakage of these cords is reduced.

The value of the indicator MC of the cords according to the invention ensures that the latter have structures corresponding to relatively low modulus values ranging from 50 GPa and 160 GPa, thus making it possible to hug the obstacles encountered, unlike the cords of the prior art which are far too stiff.

Furthermore, the value of the indicator MC of the cords according to the invention ensures that the latter have a modulus that is high enough to provide the tyre with sufficient steering capability when used in the working reinforcement.

The helix angles are defined by the following formulae:

$\alpha = {\arctan\left( \frac{2\pi\;{RI}}{PI} \right)}$ in which RI is the radius of winding of the internal strands and PI is the pitch at which each internal strand is wound.

$\beta = {\arctan\left( \frac{2\pi\; R\; 1}{p1} \right)}$ in which R1 is the radius of winding of the Q internal threads of each internal strand and p1 is the pitch at which the Q internal threads are assembled within each internal strand. When Q=1, R1=0 and therefore β=0.

$\gamma = {\arctan\left( \frac{2\pi\; R\; 2}{p2} \right)}$ in which R2 is the radius of winding of the N external threads of each internal strand and p2 is the pitch at which the N external threads are assembled within each internal strand.

$\alpha^{\prime} = {\arctan\left( \frac{2\pi\;{RE}}{PE} \right)}$ in which RE is the radius of winding of the external strands and PE is the pitch at which each external strand is wound.

$\beta^{\prime} = {\arctan\left( \frac{2\pi\; R\; 1^{\prime}}{p\; 1^{\prime}} \right)}$ in which R1′ is the radius of winding of the Q′ internal threads of each external strand and p1′ is the pitch at which the Q′ internal threads are assembled within each external strand. When Q′=1, R1′=0 and therefore β′=0.

$\gamma^{\prime} = {\arctan\left( \frac{2\pi\; R\; 2^{\prime}}{p\; 2^{\prime}} \right)}$ in which R2′ is the radius of winding of the N′ external threads of each external strand and p2′ is the pitch at which the N′ external threads are assembled within each external strand.

The radii of winding RI and RE are measured on a transverse cross section perpendicular to the main axis of the cord and correspond to the distance between the centre of the helix described by, respectively, each internal and external strand and the centre of the cord.

Similarly, the radii of winding R1 and R2 are measured on a transverse cross section perpendicular to the main axis of each internal strand considered individually and correspond to the distance between the centre of the helix described by, respectively, each internal and external thread, and the centre of the internal strand.

Similarly, the radii of winding R1′ and R2′ are measured on a transverse cross section perpendicular to the main axis of each external strand considered individually and correspond to the distance between the centre of the helix described by, respectively, each internal and external thread, and the centre of the external strand.

In the invention, the cord has two layers of strands, which means to say that it comprises an assembly made up of two layers of strands, neither more nor less, which means to say that the assembly has two layers of strands, not one, not three, but only two. The external layer of the cord is wound in a helix around the internal layer of the cord in contact with the internal layer of the cord.

Each internal and external strand has two layers, which means to say that it comprises an assembly made up of two layers of threads, neither more nor less, which means to say that the assembly has two layers of threads, not one, not three, but only two. The external layer of each strand is wound around the internal layer of this strand in contact with the internal layer of this strand.

Furthermore, unlike in the case where J=1 and in which there might be a risk of seeing the internal strand exit the cord radially under the effect of the repeated compressive loadings applied to the cord, the presence of several strands in the internal layer of the cord (J>1) wound in a helix makes it possible to reduce this risk, the compressive loadings then being distributed over the plurality of strands of the internal layer of the cord and the helix keeping the internal strands together.

As an option and a preference, in one embodiment, the cord does not have any polymeric compound, notably the cord does not have any sheath of any polymeric compound covering the internal strand. In another embodiment, the cord does not have any elastomeric compound, notably the cord does not have any sheath of any elastomeric compound covering the internal layer of the cord.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be better understood on reading the following description, given solely by way of non-limiting example and with reference to the drawings, in which:

FIG. 1 is a view in cross section perpendicular to the circumferential direction of a tyre according to the invention;

FIG. 2 is a detail view of the region II of FIG. 1;

FIG. 3 is a schematic view in cross section perpendicular to the axis of the cord (which is assumed to be straight and at rest) of a cord according to a first embodiment of the invention;

FIG. 4 is a graph illustrating the force-elongation curve of the cord of FIG. 3 according to the first embodiment,

FIG. 5 is a graph similar to that of FIG. 4 of a cord according to a second embodiment,

FIG. 6 is a view similar to that of FIG. 3 of a cord according to a third embodiment the invention, and

FIG. 7 is a graph similar to that of FIG. 4 of a cable according to a third embodiment.

DETAILED DESCRIPTION

What is meant by a polymer compound or a polymeric compound is that the compound contains at least one polymer. For preference, such a polymer may be a thermoplastic, for example a polyester or a polyamide, a thermosetting polymer, an elastomer, for example natural rubber, a thermoplastic elastomer or a combination of these polymers.

What is meant by an elastomer compound or an elastomeric compound is that the compound contains at least one elastomer or one rubber (the two terms being synonyms) and at least one other component. For preference, the elastomer compound also contains a vulcanization system and a filler. More preferentially, the elastomer is a diene elastomer.

In the description and the claims, any range of values denoted by the expression “between a and b” represents the range of values extending from more than a to less than b (namely excluding the end-points a and b), whereas any range of values denoted by the expression “from a to b” means the range of values extending from the end-point “a” as far as the end-point “b”, namely including the strict end-points “a” and “b”.

It will be recalled that, as is known, the pitch of a strand represents the length of this strand, measured parallel to the axis of the cord, after which the strand that has this pitch has made a complete turn around the said axis of the cord. Similarly, the pitch of a thread represents the length of this thread, measured parallel to the axis of the strand in which it is located, after which the thread that has this pitch has made a complete turn around the said axis of the strand.

What is meant by the direction of winding of a layer of strands or of threads is the direction that the strands or the threads form with respect to the axis of the cord or of the strand. The direction of winding is commonly designated by the letter Z or S.

The pitches, directions of winding, and diameters of the threads and of the strands are determined in accordance with standard ASTM D2969-04 of 2014. The radii of winding are measured by using a microscope to look at a cross section of the cord taken on an axis perpendicular to the axis of the cord.

What is meant by similar thread diameters is that the ratios of the diameters of the threads considered in pairs range from 0.75 to 1.25. What is meant by identical thread diameters is that the ratios of the diameters of the threads considered in pairs are equal to 1.

Advantageously, the cord is made of metal. What is meant by metal cord is, by definition, a cord formed of threads made entirely (100% of the threads) of a metallic material. Such a metal cord is preferentially implemented with threads made of steel, more preferentially of pearlitic (or ferritic-pearlitic) carbon steel referred to as “carbon steel” below, or else made of stainless steel (by definition, steel comprising at least 11% chromium and at least 50% iron). However, it is of course possible to use other steels or other alloys.

When a carbon steel is advantageously used, its carbon content (% by weight of steel) is preferably comprised between 0.2% and 1.2%, notably between 0.5% and 1.1%; these contents represent a good compromise between the mechanical properties required for the tyre and the workability of the threads.

The metal or the steel used, whether in particular it is a carbon steel or a stainless steel, may itself be coated with a metal layer which improves, for example, the workability properties of the metal cord and/or of its constituent elements, or the use properties of the cord and/or of the tyre themselves, such as the properties of adhesion, corrosion resistance or resistance to ageing. According to one preferred embodiment, the steel used is covered with a layer of brass (Zn—Cu alloy) or of zinc.

For preference, the threads of the one same layer of a predetermined (internal or external) strand all have substantially the same diameter. Advantageously, the internal strands all have substantially the same diameter. Advantageously, the external strands all have substantially the same diameter. What is meant by “substantially the same diameter” is that the threads or the strands have identical diameters to within the industrial tolerances.

In the present application, the modulus EC of a cord is calculated by measuring the gradient of the elastic portion of a force-elongation curve obtained by applying standard ASTM D2969-04 of 2014 to the cord tested, and then by apportioning this gradient to the metal cross section of the cord, namely the sum of the cross sections of the threads that make up the cord. Alternatively, the metal cross section can be determined by measuring the linear mass of the cord in accordance with standard ASTM D2969-04 of 2014, and by dividing this linear mass by the density of the steel used.

The elastic portion of the curve corresponds to a substantially linear portion of the force-elongation curve, which portion compliments the structural portion and the plastic portion of the force-elongation curve. The elastic portion corresponds to an elastic elongation Ae and is the result of the construction of the cord, notably of the angles of the various layers and of the diameters of the threads. The elastic portion, and the corresponding elongation Ae, of the force-elongation curve are notably described in documents U.S. Pat. No. 5,843,583, WO 2005/014925 and WO2007/090603 and correspond to the portion and to the elongation of the force-elongation curve comprised between:

-   -   the structural portion corresponding to the structural         elongation As, resulting from the aeration of the cord, namely         the empty space between the various threads or strands that make         up the cord, and     -   the plastic portion corresponding to the plastic elongation Ap,         resulting from the plasticity (irreversible deformation beyond         the elastic limit) of one or more threads of the cord.

For certain cords, there is no aeration in the cord, which means that the structural elongation As is zero. In all cases (As zero and As non-zero), the elastic portion corresponds to the linear portion of the force-elongation curve that has the steepest gradient.

The modulus EC of the cord is measured on an as-manufactured cord, namely a cord without any elastomeric compound in which the cord would be embedded in order to form a ply. Similarly, the modulus EI of the internal layer of the cord is measured by taking the internal layer of the cord either as-manufactured or by unravelling the external layer of external strands from the finished cord in order to obtain the internal layer of the cord alone. As an alternative, the modulus values EC and EI could be measured by extracting a cord from a tyre and removing all the elastomeric compound from around and within the cord, for example by chemical derubberizing as is well known to those skilled in the art.

As a preference, 100≤MC≤170 and more preferably, 110≤MC≤170. Within this interval, the modulus of the cord is even further away from the modulus of the cords of the prior art and makes it possible to reduce the damage caused by obstacles that highly stress the crown reinforcement of the tyre.

In preferred embodiments, 35≤MI≤195. In these preferred embodiments, the modulus of the internal layer of the cord has a modulus EI advantageously such that 25 GPa≤EI≤180 GPa.

As the cords according to the invention have an architecture in which J>1, the most severe transverse loadings applied to the cord when the latter is tensioned are the transverse loadings applied between the internal strands, notably in instances in which the external layer of the cord is desaturated, unlike a cord in which J=1 and in which the most severe transverse loadings are the transverse loadings applied by the external strands to the internal strands, notably in instances in which the external layer of the cord is desaturated.

Thus, in a first variant in which the internal layer of the cord has a relatively low modulus, 35≤MI≤135. In this first variant, the modulus EI of the internal layer of the cord is advantageously such that 25 GPa≤EI≤94 GPa. Thus, the lower the modulus of the internal layer, the better the principal loadings will be reacted and the better the breaking strength of the cord will be. The breaking strength of the cord is maximized here by using a relatively low modulus for the internal layer.

In a second variant in which the internal layer of the cord has a higher modulus, 136≤MI≤195. In this second variant, the modulus EI of the internal layer of the cord is advantageously such that 95 GPa≤EI≤180 GPa.

In preferred embodiments, 75≤ME≤188. In a particular variant, 85≤ME≤180.

In a first variant in which the external layer of the cord has a relatively low modulus, 75≤ME≤120. In this first variant, because the modulus of the external layer is relatively low, the external layer is able to resist cutting following the stress loadings of indenting features. This then maximizes the resistance to cutting of the cord. In that particular variant, 85≤ME≤120.

In a second variant in which the external layer of the cord has a higher modulus, 121≤ME≤188. Because of the relatively low modulus of the cord, a relatively high value for the modulus of the external layer leads to a relatively low value for the modulus of the internal layer and therefore to the cord having excellent force at break. In that particular variant, 121≤ME≤180.

In an embodiment in which the internal and external layers of the cord have relatively similar modulus values, 0.70≤ME/MI≤1.30. In this embodiment, the inventors are postulating the hypothesis that the core and the layer work more or less together when the cord is stressed, notably in tension. In this way, the compromise between the breaking strength of the cord and its resistance to cutting is maximized. In this embodiment, the internal layer of the cord and the cord have relatively similar EC and EI modulus values, advantageously such that 0.57≤EC/EI≤1.43. In that particular variant, 0.60≤EC/EI≤1.20.

In another embodiment in which the internal and external layers of the cord have relatively different modulus values, ME/MI≤0.69 or 1.31≤ME/MI.

In a variant, the internal layer of the cord has a relatively high modulus with respect to the modulus of the external layer of the cord, namely ME/MI≤0.69, preferably 0.39≤ME/MI≤0.69. In this variant, advantageously EC/EI≤0.65, preferably 0.36≤EC/EI≤0.65. This variant favours the resistance of the cord to cutting over its breaking strength. In that particular variant, 0.49≤ME/MI≤0.69 and 0.40≤EC/EI≤0.59.

In another variant, the internal layer of the cord has a relatively low modulus with respect to the modulus of the external layer of the cord, namely 1.31≤ME/MI, preferably 1.31≤ME/MI≤3.30. In this other variant, the internal layer of the cord has a relatively low modulus with respect to the modulus of the cord, namely advantageously such that 1.21≤EC/EI, preferably 1.21≤EC/EI≤3.00. This variant favours the breaking strength of the cord over its resistance to cutting.

In preferred embodiments of the invention, the cords have the following advantageous structural characteristics.

In one embodiment, D1, D2, D1′ and D2′ each range from 0.15 mm to 0.60 mm, preferably from 0.20 mm to 0.50 mm, more preferably from 0.23 mm to 0.45 mm and more preferably still, from 0.25 mm to 0.40 mm.

Advantageously, the internal layer of the cord is wound in a cord internal layer direction and each internal (when Q>1) and external layer of each internal strand is wound in the same direction of winding as the direction of the internal layer of the cord.

Advantageously, the external layer is wound in a cord external layer direction and each internal (when Q′>1) and external layer of each external strand is wound in the same direction of winding as the direction of the external layer of the cord.

In one embodiment, the direction of the internal layer of the cord and the direction of the external layer of the cord are opposite directions. In this embodiment, the risk of potential undesired slippage of the external strands in grooves formed between the internal strands is reduced as a result of a crossover between the internal and external strands.

In another embodiment, the direction of the internal layer of the cord and the direction of the external layer of the cord are the same. In this embodiment, manufacture is relatively easy because unlike in the preceding embodiment, there is no need to differentiate between the directions of winding of the internal and external layers of the cord. Nevertheless, contacts between the external threads of the external layers of the internal and external strands are relatively long and this may, with certain combinations of pitch, diameter and architecture of the cords, generate assembly defects caused for example by undesired slippage of the external strands in grooves formed between the internal strands.

In one preferred embodiment, the helix angle α of each internal strand in the internal layer of the cord ranges from 3° to 42°. By controlling chiefly the value of the helix angle α, the value of the modulus associated with the internal layer of the cord is largely controlled. This is because the helix angle α plays a predominant role by comparison with the angles β and γ whose contribution to the modulus is smaller. Thus, the higher the helix angle α of each internal strand, the lower the modulus associated with the internal layer. Thus, advantageously, the internal strands are wound in a helix with a pitch PI ranging from 10 mm to 65 mm, preferably from 10 mm to 45 mm. In that particular variant, the helix angle α ranges from 5° to 42°.

In one preferred embodiment, the helix angle α′ of each external strand in the external layer of the cord ranges from 7° to 38°. In a similar way to the helix angle α, by controlling chiefly the value of the helix angle α′, the value of the modulus associated with the external layer of the cord is largely controlled. This is because the helix angle α′ plays a predominant role by comparison with the angles β′ and γ′ whose contribution to the modulus is smaller. Thus, the higher the helix angle α′ of each external strand, the lower the modulus associated with the external layer. Advantageously, the L external strands are wound in a helix with a pitch PE ranging from 30 mm to 65 mm, preferably from 30 mm to 60 mm. In that particular variant, the helix angle α′ ranges from 10° to 32°.

Advantageously, 11°≤2α+β+γ≤110°. In an embodiment in which Q=1, advantageously 11°≤2α+β+γ≤74°. In an embodiment in which Q>1, advantageously 16°≤2α+β+γ≤110°. For identical or similar diameters of threads used, the angles thus defined make it possible to structurally define the internal layer of the cord and the internal strands of this layer in order to obtain a cord according to the invention that is easy to manufacture on an industrial scale by altering only the helix angles α, β and γ. In that particular variant, 20°≤2α+β+γ≤136°.

Advantageously, 23°≤2α′+β′+γ′≤97°. In an embodiment in which Q′=1, advantageously 23°≤2α′+β′+γ′≤85°. In an embodiment in which Q′>1, advantageously 28°≤2α′+β′+γ′≤97°. For identical or similar diameters of threads used, the angles thus defined make it possible to structurally define the external layer of the cord and the external strands of this layer in order to obtain a cord according to the invention that is easy to manufacture on an industrial scale by altering only the helix angles α′, β′ and γ′. In that particular variant, 39°≤2α′+β′+γ′≤100°.

Advantageously, 51°≤2α+β+γ+2α′+β′+γ′≤184°. In an embodiment in which Q=1 and Q′=1, advantageously 51°≤2α+β+γ+2α′+β′+γ′≤145°. In an embodiment in which Q>1 and Q′=1, advantageously 55°≤2α+β+γ+2α′+β′+γ′≤154°. In an embodiment in which Q=1 and Q′>1, advantageously 60°≤2α+β+γ+2α′+β′+γ′≤151°. In an embodiment in which Q>1 and Q′>1, advantageously 68°≤2α+β+γ+2α′+β′+γ′≤184°. For identical or similar diameters of threads used, the angles thus defined make it possible to structurally define a cord according to the invention that is easy to manufacture on an industrial scale by altering only the helix angles α, α′, β, β′, γ and γ′. In that particular variant, 73°≤2α+β+γ+2α′+β′+γ′≤195°.

In an embodiment in which Q>1, the helix angle β of each internal thread in the internal layer within each internal strand ranges from 4° to 25°, preferably 4° to 17°. Advantageously, the Q internal threads of each internal strand are assembled within each internal strand at a pitch p1 ranging from 2 to 20 mm, preferably from 5 to 20 mm.

In that particular variant, β ranges from 4° to 25° and p1 ranges from 2 to 20 mm.

In an embodiment in which Q=1, the helix angle γ of each external thread in the external layer within each internal strand ranges from 6° to 31° and in a preferred variant from 5° to 26°. Advantageously, the N external threads of each internal strand are assembled within each internal strand at a pitch p2 ranging from 4 to 40 mm, preferably from 5 to 30 mm.

In an embodiment in which Q>1, the helix angle γ of each external thread in the external layer within each internal strand ranges from 5° to 31°. Advantageously, the N external threads of each internal strand are assembled within each internal strand at a pitch p2 ranging from 4 to 40 mm.

In that particular variant, γ ranges from 6° to 31° and p2 ranges from 4 to 40 mm.

In an embodiment in which Q′>1, the helix angle β′ of each internal thread in the internal layer within each external strand ranges from 4° to 25°, preferably from 4° to 17°. Advantageously, the Q′ internal threads of each external strand are assembled within each external strand at a pitch p1′ ranging from 2 to 20 mm, preferably from 5 to 20 mm.

In that particular variant, β′ ranges from 4° to 25° and p1 ranges from 2 to 20 mm.

In an embodiment in which Q′=1, the helix angle γ′ of each external thread in the external layer within each external strand ranges from 6° to 31° and in a preferred variant from 5° to 26°. Advantageously, the N′ external threads of each internal strand are assembled within each external strand at a pitch p2′ ranging from 4 to 40 mm, preferably from 5 to 30 mm.

In an embodiment in which Q>1, the helix angle γ′ of each external thread in the external layer within each external strand ranges from 5° to 31°. Advantageously, the N′ external threads of each internal strand are assembled within each external strand at a pitch p2′ ranging from 4 to 40 mm.

In that particular variant, γ′ ranges from 6° to 31° and p2 ranges from 4 to 40 mm.

The combinations of helix angles and of pitches described above lead to cords having the advantageous modulus values of the invention. In addition, the pitches p1, p1′, p2 and p2′ within these preferred ranges make it possible to obtain a cord that exhibits mechanical properties compatible with tyre use, a relatively low cost and a relatively low linear cord weight.

Cords According to an Embodiment A of the Invention

In one embodiment, the cord has a relatively very low modulus, and is such that 100≤MC≤156. In this embodiment, the ability of the cord to hug the obstacles encountered is favoured over the ability of the cord to provide the tyre with high steering capability. Such cords according to embodiment A advantageously have modulus values ranging from 50 GPa to 89 GPa and are thus referred to as very low-modulus cords. In a particular variant of the cords according to embodiment A, 100≤MC≤135.

In preferred variants of cords according to embodiment A, 62≤MI≤192. In these preferred variants, advantageously 25 GPa≤EI≤180 GPa. In that particular variant of the cords according to embodiment A, 40≤MI≤185 and 25 GPa≤EI≤175 GPa.

In a first variant in which the internal layer of the cord according to embodiment A has a relatively low modulus, 62≤MI≤135. In this first variant, advantageously 27 GPa≤EI≤94 GPa. As explained above, the breaking strength of the cord is maximized here by using a relatively low modulus for the internal layer. In that particular variant of the cords according to embodiment A, 40≤MI≤135 and 25 GPa≤EI≤102 GPa.

In a second variant in which the internal layer of the cord according to embodiment A has a higher modulus, 136≤MI≤192. In this second variant, advantageously 95 GPa≤EI≤180 GPa. Because of the relatively very low modulus of the cord, a relatively high value for the modulus of the internal layer entails a relatively low value for the modulus of the external layer therefore leading to excellent resistance of the cord to cutting. In that particular variant of the cords according to embodiment A, 136≤MI≤185 and 103 GPa≤EI≤175 GPa.

In preferred variants of cords according to embodiment A, 75≤ME≤171. In that particular variant of the cords according to embodiment A, 90≤ME≤170.

In a first variant in which the external layer of the cord according to embodiment A has a relatively low modulus, 75≤ME≤120. As explained above, the resistance of the cord to cutting is maximized here by using a relatively low modulus for the external layer. In that particular variant of the cords according to embodiment A, 90≤ME≤120.

In a second variant in which the external layer of the cord according to embodiment A has a higher modulus, 121≤ME≤171. Because of the relatively very low modulus of the cord, a relatively high value for the modulus of the external layer entails a relatively low value for the modulus of the internal layer therefore leading to excellent breaking strength of the cord. In that particular variant of the cords according to embodiment A, 121≤ME≤170.

In an embodiment in which the internal and external layers of the cord according to embodiment A have relatively similar modulus values, 0.70≤ME/MI≤1.30. In this variant, the inventors are postulating the hypothesis that the core and the layer work more or less together when the cord according to embodiment A is stressed, notably in tension. In this variant, advantageously then 0.57≤EC/EI≤1.23. In this way, the compromise between the breaking strength of the cord and its resistance to cutting is maximized. In that particular variant of the cords according to embodiment A, 0.70≤ME/MI≤1.30 and 0.60≤EC/EI≤1.20.

In an embodiment in which the internal and external layers of the cord according to embodiment A have relatively different modulus values, ME/MI≤0.69 or 1.31≤ME/MI.

In a variant, the internal layer of the cord according to embodiment A has a relatively high modulus with respect to the modulus of the external layer of the cord according to embodiment A, namely ME/MI≤0.69, preferably 0.39≤ME/MI≤0.69. In this variant, advantageously then EC/EI≤0.56, preferably 0.36≤EC/EI≤0.56. This variant favours the resistance of the cord to cutting over its breaking strength. In that particular variant of the cords according to embodiment A, ME/MI≤0.69, preferably 0.49≤ME/MI≤0.69, EC/EI≤0.59, preferably 0.40≤EC/EI≤0.59.

In another variant, the internal layer of the cord according to embodiment A has a relatively low modulus with respect to the modulus of the external layer of the cord according to embodiment A, namely 1.31≤ME/MI, preferably 1.31≤ME/MI≤2.52. In this variant, advantageously then 1.24≤EC/EI, preferably 1.24≤EC/EI≤3.00. This variant favours the breaking strength of the cord over its resistance to cutting. In that particular variant of the cords according to embodiment A, 1.31≤ME/MI, preferably 1.31≤ME/MI≤3.30, 1.21≤EC/EI, preferably 1.21≤EC/EI≤3.00.

In preferred variants of the cords according to embodiment A, the cords according to embodiment A and with a very low modulus have the following advantageous structural characteristics.

Preferably, the helix angle α of each internal strand in the internal layer of the cord according to embodiment A ranges from 3° to 42°. In that particular variant of the cords according to embodiment A, α ranges from 9° to 42°.

In one preferred embodiment, the helix angle α′ of each external strand in the external layer of the cord according to embodiment A ranges from 13° to 38°. In that particular variant of the cords according to embodiment A, α′ ranges from 13° to 32°.

As specified hereinabove, by controlling chiefly the value of the helix angles α and α′, the value of the modulus associated with the internal and external layers of the cord is largely controlled. Thus, for relatively high helix angles α and α′, relatively very low modulus values associated with these layers are obtained, making it possible to obtain a cord according to embodiment A, and which has a very low modulus.

Advantageously, 16°≤2α+β+γ≤110°. In an embodiment in which Q=1, advantageously 16°≤2α+β+γ≤74°. In an embodiment in which Q>1, advantageously 23°≤2α+β+γ≤110°. For identical or similar diameters of threads used, the angles thus defined make it possible to structurally define the internal layer of the cord and the internal strands of this layer in order to obtain a cord according to embodiment A with a very low modulus of the invention that is easy to manufacture on an industrial scale by altering only the helix angles α, β and γ. In that particular variant of the cords according to embodiment A and with a very low modulus, 29°≤2α+β+γ≤136°.

Advantageously, 43°≤2α′+β′+γ′≤97°. In an embodiment in which Q′=1, advantageously 47°≤2α′+β′+γ′≤85°. In an embodiment in which Q′>1, advantageously 43°≤2α′+β′+γ′≤97°. For identical or similar diameters of threads used, the angles thus defined make it possible to structurally define the external layer of the cord and the external strands of this layer in order to obtain a cord according to embodiment A with a very low modulus of the invention that is easy to manufacture on an industrial scale by altering only the helix angles α′, β′ and γ′. In that particular variant of the cords according to embodiment A and with a very low modulus, 42°≤2α′+β′+γ′≤90°.

Advantageously, 85°≤2α+β+γ+2α′+β′+γ′≤184°. In an embodiment in which Q=1 and Q′=1, advantageously 85°≤2α+β+γ+2α′+β′+γ′≤145°. In an embodiment in which Q>1 and Q′=1, advantageously 108°≤2α+β+γ+2α′+β′+γ′≤154°. In an embodiment in which Q=1 and Q′>1, advantageously 90°≤2α+β+γ+2α′+β′+γ′≤151°. In an embodiment in which Q>1 and Q′>1, advantageously 110°≤2α+β+γ+2α′+β′+γ′≤184°. For identical or similar diameters of threads used, the angles thus defined make it possible to structurally define a cord according to embodiment A that has a very low modulus of the invention and that is easy to manufacture on an industrial scale by altering only the helix angles α, α′, β, β′, γ and γ′. In that particular variant of the cords according to embodiment A and with a very low modulus, 109°≤2α+β+γ+2α′+β′+γ′≤195°.

The values for the helix angles β, γ, β′, γ′ and those for the pitches p1, p2, p1′, p2′ that make it possible to obtain cords according to embodiment A with a very low modulus are identical to those already described hereinabove.

Cords According to an Embodiment B of the Invention

In another embodiment, the cord has a relatively low modulus, and is such that 130≤MC≤172. In this embodiment, a balanced compromise between the ability of the cord to hug the obstacles encountered and the ability of the cord to provide the tyre with high steering capability is adopted. Such cords according to embodiment B advantageously have modulus values ranging from 90 GPa to 130 GPa and are thus referred to as low-modulus cords. In a particular variant of the cords according to embodiment B, 130≤MC≤160.

In preferred variants of cords according to embodiment B, 75≤MI≤195. Advantageously then 25 GPa≤EI≤180 GPa. In that particular variant of the cords according to embodiment B, 75≤MI≤185 and 35 GPa≤EI≤175 GPa.

In a first variant in which the internal layer of the cord according to embodiment B has a relatively low modulus, 75≤MI≤135. In this first variant, advantageously then 25 GPa≤EI≤94 GPa. As explained above, the breaking strength of the cord is maximized here by using a relatively low modulus for the internal layer. In that particular variant of the cords according to embodiment B, 75≤MI≤135. And 35 GPa≤EI≤102 GPa.

In a second variant in which the internal layer of the cord according to embodiment B has a higher modulus, 136≤MI≤195. In this second variant, then 95 GPa≤EI≤180 GPa. In that particular variant of the cords according to embodiment B, 136≤MI≤185 and 103 GPa≤EI≤175 GPa.

In preferred variants of cords according to embodiment B, 115≤ME≤178. In that particular variant of the cords according to embodiment B, 130≤ME≤180

In an embodiment in which the internal and external layers of the cord according to embodiment B have relatively similar modulus values, 0.70≤ME/MI≤1.30. In this variant, advantageously then 0.58≤EC/EI≤1.29. In this variant, the inventors are postulating the hypothesis that the core and the layer work more or less together when the cord according to embodiment B is stressed, notably in tension. In this way, the compromise between the breaking strength of the cord and its resistance to cutting is maximized. In a particular variant of the cords according to embodiment B, 0.70≤ME/MI≤1.30 and 0.60≤EC/EI≤1.20.

In an embodiment in which the internal and external layers of the cord according to embodiment B have relatively different modulus values, ME/MI≤0.69 or 1.31≤ME/MI.

In a variant, the internal layer of the cord according to embodiment B has a relatively high modulus with respect to the modulus of the external layer of the cord according to embodiment B, namely ME/MI≤0.69, preferably 0.63≤ME/MI≤0.69. In this variant, advantageously then EC/EI≤0.65, preferably 0.51≤EC/EI≤0.65. This variant favours the resistance of the cord to cutting over its breaking strength.

In another variant, the internal layer of the cord according to embodiment B has a relatively low modulus with respect to the modulus of the external layer of the cord according to embodiment B, namely 1.31≤ME/MI, preferably 1.31≤ME/MI≤2.35. In this variant, advantageously then 1.21≤EC/EI, preferably 1.21≤EC/EI≤2.82. This variant therefore favours the breaking strength of the cord over its resistance to cutting.

In preferred variants, the cords according to embodiment B with a low modulus have the following advantageous structural characteristics.

Preferably, the helix angle α of each internal strand in the internal layer of the cord according to embodiment B ranges from 3° to 36°. In that particular variant of the cords according to embodiment B, α ranges from 5° to 36°.

In one preferred embodiment, the helix angle α′ of each external strand in the external layer of the cord according to embodiment B ranges from 9° to 27°. In that particular variant of the cords according to embodiment B, α ranges from 10° to 25°.

As specified hereinabove, by controlling chiefly the value of the helix angles α and α′, the value of the modulus associated with the internal and external layers of the cord is largely controlled. Thus, for relatively medium helix angles α and α′, relatively low modulus values associated with these layers are obtained, making it possible to obtain a cord according to embodiment B, and which has a low modulus.

Advantageously, 13°≤2α+β+γ≤110°. In an embodiment in which Q=1, advantageously 13°≤2α+β+γ≤74°. In an embodiment in which Q>1, advantageously 16°≤2α+β+γ≤110°. For identical or similar diameters of threads used, the angles thus defined make it possible to structurally define the internal layer of the cord and the internal strands of this layer in order to obtain a cord according to embodiment B with a low modulus that is easy to manufacture on an industrial scale by altering only the helix angles α, β and γ. In that particular variant of the cords according to embodiment B with a low modulus, 27°≤2α+β+γ≤108°.

Advantageously, 31°≤2α′+β′+γ′≤71°. In an embodiment in which Q′=1, advantageously 31°≤2α′+β′+γ′≤66°. In an embodiment in which Q′>1, advantageously 39°≤2α′+β′+γ′≤71°. For identical or similar diameters of threads used, the angles thus defined make it possible to structurally define the external layer of the cord and the external strands of this layer in order to obtain a cord according to embodiment B with a low modulus that is easy to manufacture on an industrial scale by altering only the helix angles α′, β′ and γ′. In that particular variant of the cords according to embodiment B with a low modulus, 39°≤2α′+β′+γ′≤65°.

Advantageously, 65°≤2α+β+γ+2α′+β′+γ′≤153°. In an embodiment in which Q=1 and Q′=1, advantageously 65°≤2α+β+γ+2α′+β′+γ′≤117°. In an embodiment in which Q>1 and Q′=1, advantageously 72°≤2α+β+γ+2α′+β′+γ′≤133°. In an embodiment in which Q=1 and Q′>1, advantageously 81°≤2α+β+γ+2α′+β′+γ′≤130°. In an embodiment in which Q>1 and Q′>1, advantageously 79°≤2α+β+γ+2α′+β′+γ′≤153°. For identical or similar diameters of threads used, the angles thus defined make it possible to structurally define a cord according to embodiment B with a low modulus that is easy to manufacture on an industrial scale by altering only the helix angles α, α′, β, β′, γ and γ′. In that particular variant of the cords according to embodiment B with a low modulus, 82°≤2α+β+γ+2α′+β′+γ′≤153°.

The values for the helix angles β, γ, β′, γ′ and those for the pitches p1, p2, p1′, p2′ that make it possible to obtain cords according to embodiment B with a low modulus are identical to those already described hereinabove.

Cords According to an Embodiment C of the Invention

In yet another embodiment, the cord has a relatively medium modulus, and is such that 150≤MC≤175. In this embodiment, the ability of the cord to provide the tyre with high steering capability is favoured over the ability of the cord to hug the obstacles encountered. Such cords according to embodiment C advantageously have modulus values ranging from 131 GPa to 159 GPa and are thus referred to as medium-modulus cords.

In preferred variants of cords according to embodiment C, 120≤MI≤195. Advantageously then 78 GPa≤EI≤180 GPa. In that particular variant of the cords according to embodiment C, 153≤MI≤193 and 125 GPa≤EI≤180 GPa.

In a first variant in which the internal layer of the cord according to embodiment C has a relatively low modulus, 120≤MI≤135. In this first variant, advantageously then 78 GPa≤EI≤94 GPa. As explained above, the breaking strength of the cord is maximized here by using a relatively low modulus for the internal layer.

In a second variant in which the internal layer of the cord according to embodiment C has a higher modulus, 136≤MI≤195. In this second variant, then 95 GPa≤EI≤180 GPa.

In preferred variants of cords according to embodiment C, 144≤ME≤188. In that particular variant of the cords according to embodiment C, 149≤ME≤180.

In an embodiment in which the internal and external layers of the cord according to embodiment C have relatively similar modulus values, 0.70≤ME/MI≤1.30, preferably 0.76≤ME/MI≤1.30. In this variant, advantageously then 0.72≤EC/EI≤1.43. In this variant embodiment, the inventors are postulating the hypothesis that the core and the layer work more or less together when the cord according to embodiment C is stressed, notably in tension. In this way, the compromise between the breaking strength of the cord and its resistance to cutting is maximized. In that particular variant of the cords according to embodiment C, 0.70≤ME/MI≤1.30, preferably 0.80≤ME/MI≤1.15 and 0.60≤EC/EI≤1.20, preferably 0.80≤EC/EI≤1.15.

In one embodiment in which the internal and external layers of the cord according to embodiment C have relatively different modulus values, 1.31≤ME/MI.

In a variant, the internal layer of the cord according to embodiment C has a relatively small modulus with respect to the modulus of the external layer of the cord according to embodiment C, namely 1.31≤ME/MI, preferably 1.31≤ME/MI≤1.48. In this variant, advantageously then 1.44≤EC/EI, preferably 1.44≤EC/EI≤1.82. In this variant, the internal layer of the cord according to embodiment C has a relatively small modulus with respect to the modulus of the external layer of the cord according to embodiment C, namely advantageously such that EC/EI≤0.7965, preferably 0.362≤EC/EI≤0.6579. This variant therefore favours the breaking strength of the cord over its resistance to cutting.

In preferred variants, the cords according to embodiment C with a medium modulus have the following advantageous structural characteristics.

Preferably, the helix angle α of each internal strand in the internal layer of the cord according to embodiment C ranges from 3° to 24°. In that particular variant of the cords according to embodiment C, α ranges from 5° to 19°.

In one preferred embodiment, the helix angle α′ of each external strand in the external layer of the cord according to embodiment C ranges from 11° to 20°. In that particular variant of the cords according to embodiment C, α′ ranges from 7° to 22°.

As specified hereinabove, by controlling chiefly the value of the helix angles α and α′, the value of the modulus associated with the internal and external layers of the cord is largely controlled. Thus, for relatively small helix angles α and α′, relatively medium modulus values associated with these layers are obtained, making it possible to obtain a cord according to embodiment C, and which has a medium modulus.

Advantageously, 11°≤2α+β+γ≤64°. In an embodiment in which Q=1, advantageously 11°≤2α+β+γ≤64°. In an embodiment in which Q>1, advantageously 16°≤2α+β+γ≤63°. For identical or similar diameters of threads used, the angles thus defined make it possible to structurally define the internal layer of the cord and the internal strands of this layer in order to obtain a cord according to embodiment C with a medium modulus that is easy to manufacture on an industrial scale by altering only the helix angles α, β and γ. In that particular variant of the cords according to embodiment C with a medium modulus, 23°≤2α+β+γ≤55°.

Advantageously, 23°≤2α′+β′+γ′≤58°. In an embodiment in which Q′=1, advantageously 23°≤2α′+β′+γ′≤52°. In an embodiment in which Q′>1, advantageously 27°≤2α′+β′+γ′≤58°. For identical or similar diameters of threads used, the angles thus defined make it possible to structurally define the external layer of the cord and the external strands of this layer in order to obtain a cord according to embodiment C with a medium modulus that is easy to manufacture on an industrial scale by altering only the helix angles α′, β′ and γ′. In that particular variant of the cords according to embodiment C with a medium modulus, 39°≤2α′+β′+γ′≤57°.

Advantageously, 45°≤2α+β+γ+2α′+β′+γ′≤108°. In an embodiment in which Q=1 and Q′=1, advantageously 45°≤2α+β+γ+2α′+β′+γ′≤95°. In an embodiment in which Q>1 and Q′=1, advantageously 55°≤2α+β+γ+2α′+β′+γ′≤95°. In an embodiment in which Q=1 and Q′>1, advantageously 56°≤2α+β+γ+2α′+β′+γ′≤102°. In an embodiment in which Q>1 and Q′>1, advantageously 60°≤2α+β+γ+2α′+β′+γ′≤108°. For identical or similar diameters of threads used, the angles thus defined make it possible to structurally define a cord according to embodiment C with a medium modulus that is easy to manufacture on an industrial scale by altering only the helix angles α, α′, β, β′, γ and γ′, δ. In that particular variant of the cords according to embodiment C with a medium modulus, 73°≤2α+β+γ+2α′+β′+γ′≤102°.

The values for the helix angles β, γ, β′, γ′ and those for the pitches p1, p2, p1′, p2′ that make it possible to obtain cords according to embodiment C with a medium modulus are identical to those already described hereinabove.

Architecture of the Cords According to the Invention

Advantageously, J=2, 3 or 4, preferably J=3 or 4.

In one embodiment, L is equal to 7, 8, 9 or 10, preferably L=8, 9 or 10 and more preferentially L=8 or 9.

In a first variant, J=2 and L=7 or 8, preferably J=2, L=7.

In a second variant, J=3 and L=7, 8 or 9, preferably J=3, L=8 or 9. Instances in which L=8 favour the desaturation of the external layer of the cord and therefore the penetrability of the cord between the external strands. Instances in which L=9 maximize the number of external strands and therefore the breaking strength of the cord.

In a third variant, J=4 and L=7, 8, 9 or 10, preferably J=4, L=9.

In these embodiments, notably those in which J=3 or 4, there is a risk of seeing a significant spread of corrosive agents between the J=3 or 4 internal strands which delimit a central capillary which very much encourages them to spread along the cord, when the cord is insufficiently penetrated. This disadvantage can be overcome by rendering the cord capable of being penetrated by the elastomer compound which then prevents the corrosive agents from accessing the central capillary and, in the best of cases in which the central capillary is itself penetrated, prevents these corrosive agents from spreading along the cord.

Advantageously, the external layer of the cord is desaturated.

By definition, a desaturated layer of strands is such that there is enough space between the strands to allow an elastomer compound to pass. An external layer of strands is desaturated means that the external strands do not touch and that there is enough space between two adjacent external strands to allow an elastomer compound to pass as far as the internal strands. By contrast, a saturated layer of strands is such that there is not enough space between the strands of the layer to allow an elastomer compound to pass, for example because each pair of two strands of the layer touch one another.

Advantageously, the inter-strand distance of the external layer of external strands, defined, on a cross section of the cord perpendicular to the main axis of the cord, as being the shortest distance separating, on average, the circular envelopes in which two adjacent external strands are inscribed, is, for a desaturated layer of strands, greater than or equal to 30 μm. For preference, the mean inter-strand distance E separating two adjacent external strands is greater than or equal to 70 μm, more preferentially than/to 100 μm, more preferentially still than/to 150 μm, and highly preferentially than/to 200 μm.

As already explained hereinabove, as the cords according to the invention have an architecture in which J>1, the most severe transverse loadings applied to the cord when the latter is tensioned are the transverse loadings applied between the internal strands, unlike a cord in which J=1 and in which the most severe transverse loadings are the transverse loadings applied by the external strands to the internal strands. Cords exhibiting an architecture in which J>1 and comprising a number of external strands such that the external layer of the cord is saturated so as to maximize the breaking strength by adding a maximum number of external strands are known from the prior art. Here, thanks to the fact that the external layer of the cord is desaturated, the cord has, on the one hand, spaces between the external strands that allow the elastomer compound to pass, therefore allowing the cord to be rendered less sensitive to corrosion. On the other hand, although the number of external strands is reduced, the desaturation of the external layer of the cord allows the elastomer compound to penetrate, on the one hand, between the external strands and, on the other hand, between the internal strands so as to form a cushion of elastomer compound that at least partially absorbs the transverse loadings applied between the internal strands. Thus, by comparison with a similar cord having a saturated external layer of the cord, the breaking strength obtained is equivalent and the resistance to corrosion is greatly improved.

In an embodiment that promotes the penetrability of the cord, the external layer of the cord is completely unsaturated.

By definition, a completely unsaturated layer of strands is, as opposed to an incompletely unsaturated layer, such that there is sufficient space in this layer to add in at least one (X+1)th strand having the same diameter as the X strands of the layer, it thus being possible for a plurality of strands to be, or to not be, in contact with one another. In this particular instance, there is enough space in the external layer of the cord to add in at least one (L+1)th strand having the same diameter as the L external strands of the external layer of the cord.

Thus, advantageously, the sum SIE of the inter-strand distances E of the external layer of the cord is such that SIE≥DE. The sum SIE is the sum of the inter-strand distances E separating each pair of adjacent strands of the layer. The inter-strand distance of a layer is defined, in a section of the cord perpendicular to the main axis of the cord, as being the shortest distance, which, on average, separates two adjacent strands of the layer. Thus, the inter-strand distance E is calculated by dividing the sum SIE by the number of spaces separating the strands of the layer.

In another embodiment that promotes the compromise between penetrability and breaking strength, the external layer of the cord is incompletely unsaturated.

A layer that is incompletely unsaturated with strands is such that there is not enough space in this layer to add in at least one (X+1)th strand having the same diameter as the X strands of the layer. In this particular instance, there is not enough space in the external layer to add in at least one (L+1)th external strand having the same diameter as the L external strands of the external layer of the cord.

By definition, the diameter of the internal layer DI is the diameter of the smallest circle inside which the internal strands are circumscribed. The diameter of an external strand DE is the diameter of the smallest circle inside which the external strand is circumscribed. For relatively high values of DI/DE, the passage of the elastomer compound between the external strands is further promoted, and, for relatively low values of DI/DE, the architectural stability of the cord is ensured, the breaking strength is maximized while at the same time allowing the elastomer compound to pass between the external strands, the external diameter of the cord is limited, and the thickness of the ply is reduced, as therefore are the heating, rolling resistance and mass of the tyre.

Internal Strands of the Cords According to the Invention

In preferred embodiments, Q=1, 2, 3 or 4.

In one embodiment, Q=1, N=5 or 6, preferably Q=1, N=6.

In preferred embodiments that make it possible to increase the breaking strength of the cord with respect to the embodiment in which Q=1, Q=2, 3 or 4, preferably Q=3 or 4.

In these preferred embodiments in which Q>1, notably those in which Q=3 or 4, there is a risk, when the strand is insufficiently penetrated, of seeing a significant spread of corrosive agents between the Q=3 or 4 internal threads which delimit a central capillary which very much encourages them to spread along each strand. This disadvantage can be overcome by rendering the strand capable of being penetrated by the elastomer compound which then prevents the corrosive agents from accessing the central capillary and, in the best of cases in which the central capillary is itself penetrated, prevents these corrosive agents from spreading along the strand.

In preferred embodiments in which Q>1, N=7, 8, 9 or 10, preferably N=8, 9 or 10 and more preferentially N=8 or 9.

In a first variant, Q=2 and N=7 or 8, preferably Q=2, N=7.

In a second variant, Q=3 and N=7. 8 or 9, preferably Q=3, N=8.

In a third variant, Q=4 and N=7. 8, 9 or 10, preferably Q=4, N=9.

Advantageously, the external layer of each internal strand is desaturated, preferably completely unsaturated.

By definition, a desaturated layer of threads is such that there is enough space between the threads to allow an elastomer compound to pass. Thus, a layer that is desaturated means that the threads of this layer do not touch and that there is enough space between two adjacent threads of the layer to allow an elastomer compound to pass through the layer. By contrast, a saturated layer of threads is such that there is not enough space between the threads of the layer to allow an elastomer compound to pass, for example because each pair of two threads of the layer touch one another.

Advantageously, the inter-thread distance of the external layer of each internal strand is greater than or equal to 5 μm. For preference, the inter-thread distance of the external layer of each internal strand is greater than or equal to 15 μm, more preferentially greater than or equal to 35 μm, more preferentially still greater than or equal to 50 μm and highly preferentially greater than or equal to 60 μm.

The fact that the external layer of the internal strand is desaturated advantageously makes it easier for the elastomer compound to pass as far as the centre of the internal strand, and thus render the internal strand less sensitive to corrosion.

By definition, a layer of threads that is completely unsaturated is such that there is enough space in this layer to add in at least one (X+1)th thread having the same diameter as the X threads of the layer, it thus being possible for a plurality of threads to be in contact, or not in contact, with one another. In this particular instance, there is enough space in the external layer of each internal strand to add in at least one (N+1)th external thread having the same diameter as the N external threads of the external layer.

The fact that the external layer of each internal strand is completely unsaturated makes it possible to maximize the penetration of the elastomer compound into each internal strand, and thus render each internal strand even less sensitive to corrosion.

Thus, advantageously, the sum SI2 of the inter-thread distances of the external layer of each internal strand is such that SI2≥D2. The sum SI2 is the sum of the inter-thread distances separating each pair of adjacent threads of the layer. The inter-thread distance of a layer is defined, in a section of the cord perpendicular to the main axis of the cord, as being the shortest distance which, on average, separates two adjacent threads of the layer. Thus, the inter-thread distance is calculated by dividing the sum SI2 by the number of spaces separating the threads of the layer.

By contrast, an incompletely unsaturated layer threads would be such that there would not be sufficient space in this layer to add in at least one (X+1)th thread having the same diameter as the X′ threads of the layer. In this particular instance, there would not be enough space in the external layer to add in at least one (N+1)th external thread having the same diameter as the N external threads of the external layer.

In preferred embodiments, each internal thread of each internal strand has a diameter D1 greater than or equal to the diameter D2 of each external thread of each internal strand. The use of diameters such that D1>D2 makes it possible to promote the penetrability of the elastomer compound through the intermediate layer. The use of diameters such that D1=D2 makes it possible to limit the number of different threads to be managed in the manufacture of the cord.

Advantageously, each internal strand is of the type not rubberized in situ. What is meant by not rubberized in situ is that, prior to the assembly of the internal layer of the cord, and prior to the assembly of the cord, each internal strand is made up of the threads of the various layers and does not have any polymer compound, notably any elastomer compound.

External Strands of the Cord According to the Invention

In one embodiment, Q′=1. In this embodiment, N′=5 or 6, preferably N′=6.

In preferred embodiments that make it possible to increase the breaking strength of the cord with respect to the embodiment in which Q′=1, Q=2′, 3 or 4, preferably Q′=3 or 4.

In these preferred embodiments in which Q′>1, notably those in which Q′=3 or 4, there is a risk, when the strand is insufficiently penetrated, of seeing a significant spread of corrosive agents between the Q′=3 or 4 internal threads which delimit a central capillary which very much encourages them to spread along each strand. This disadvantage can be overcome by rendering the strand capable of being penetrated by the elastomer compound which then prevents the corrosive agents from accessing the central capillary and, in the best of cases in which the central capillary is itself penetrated, prevents these corrosive agents from spreading along the strand.

In preferred embodiments of the embodiment in which Q′>1, N′=7, 8, 9 or 10, preferably N′=8, 9 or 10 and more preferentially N′=8 or 9.

In a first variant, Q′=2 and N′=7 or 8, preferably Q′=2, N′=7.

In a second variant, Q′=3 and N′=7. 8 or 9, preferably Q′=3, N′=8.

In a third variant, Q′=4 and N′=7. 8, 9 or 10, preferably Q′=4, N′=9.

Advantageously, the external layer of each external strand is desaturated, preferably completely unsaturated.

As has already been specified, by definition, a desaturated layer of threads of threads is such that there is enough space between the threads to allow an elastomer compound to pass. Thus, a layer that is desaturated means that the threads of this layer do not touch and that there is enough space between two adjacent threads of the layer to allow an elastomer compound to pass through the layer. By contrast, a saturated layer of threads is such that there is not enough space between the threads of the layer to allow an elastomer compound to pass, for example because each pair of two threads of the layer touch one another.

Advantageously, the inter-thread distance of the external layer of each external strand is greater than or equal to 5 μm. For preference, the inter-thread distance of the external layer of each external strand is greater than or equal to 15 μm, more preferentially greater than or equal to 35 μm, more preferentially still greater than or equal to 50 μm and highly preferentially greater than or equal to 60 μm.

The fact that the external layer of each external strand is desaturated advantageously makes it easier for the elastomer compound to pass as far as the centre of each external strand, and thus render each external strand less sensitive to corrosion.

By definition, a completely unsaturated layer of threads is such that there is sufficient space in this layer to add in at least one (X′+1)th thread having the same diameter as the X′ threads of the layer, it thus being possible for a plurality of threads to be in contact, or not in contact, with one another. In this particular instance, there is enough space in the external layer of each external strand to add in at least one (N′+1)th external thread having the same diameter as the N′ external threads of the external layer.

The fact that the external layer of each external strand is completely unsaturated makes it possible to maximize the penetration of the elastomer compound into each external strand, and thus render each external strand even less sensitive to corrosion.

Thus, advantageously, the sum SI2′ of the inter-thread distances of the external layer of each internal strand is such that SI2′≥D2′. The sum SI2′ is the sum of the inter-thread distances separating each pair of adjacent threads of the layer. The inter-thread distance of a layer is defined, in a section of the cord perpendicular to the main axis of the cord, as being the shortest distance which, on average, separates two adjacent threads of the layer. Thus, the inter-thread distance is calculated by dividing the sum SI2′ by the number of spaces separating the threads of the layer.

By contrast, an incompletely unsaturated layer would be such that there would not be enough space in this layer to add in at least one (X′+1)th thread having the same diameter as the X′ threads of the layer. In this particular instance, there would not be enough space in the external layer to add in at least one (N′+1)th external thread having the same diameter as the N′ external threads of the external layer.

In preferred embodiments, each internal thread of each external strand has a diameter D1′ greater than or equal to the diameter D2′ of each external thread of each external strand. The use of diameters such that D1′>D2′ makes it possible to promote the penetrability of the elastomer compound through the external layer. The use of diameters such that D1′=D2′ makes it possible to limit the number of different threads to be managed in the manufacture of the cord.

Advantageously, each external strand is of the type not rubberized in situ. What is meant by not rubberized in situ is that, prior to the assembly of the external layer of the cord, and prior to the assembly of the cord, each external strand is made up of the threads of the various layers and does not have any polymer compound, notably any elastomer compound.

Tyre According to the Invention

Another subject of the invention is a tyre comprising a cord as defined above.

The cord is most particularly intended for industrial vehicles selected from heavy vehicles such as “heavy-duty vehicles”—i.e. underground trains, buses, road haulage vehicles (lorries, tractors, trailers), off-road vehicles —, agricultural vehicles or construction plant vehicles, or other transport or handling vehicles.

As a preference, the tyre is for a vehicle of the construction plant type. The tyre has a size of the W R U type in which, as is known to those skilled in the art, W denotes:

-   the nominal aspect ratio H/B as defined by the ETRTO, when it is in     the form H/B, H being the cross-sectional height of the tyre and B     being the cross-sectional width of the tyre, -   H.00 or B.00, when it is in the form H.00 or B.00, in which H=B, H     and B being as defined above,     U represents the diameter, in inches, of the rim seat on which the     tyre is intended to be mounted, and R denotes the type of carcass     reinforcement of the tyre, in this case radial. Examples of such     dimensions are, for example, 40.00 R 57 or else 59/80 R 63.

Preferably, U≥35, more preferentially U≥49 and even more preferentially U≥57.

Highly preferably, in one embodiment, the tyre is obtained by a method involving a step of embedding a cord as described hereinabove in a polymer matrix, preferably in an elastomer matrix, the cord, prior to the embedding step, being rid of any polymer or elastomer composition that may individually cover one or more, collectively cover several, internal strands of the internal layer of the cord.

Advantageously, the tyre comprises a carcass reinforcement anchored in two beads and surmounted radially by a crown reinforcement which is itself surmounted by a tread, the crown reinforcement being joined to the said beads by two sidewalls and comprising at least one cord as defined above.

Advantageously, the carcass reinforcement comprises at least one carcass ply comprising filamentary metal carcass reinforcing elements arranged substantially parallel to one another in the carcass ply, each filamentary metal carcass reinforcing element making an angle of between 80° and 90° with the circumferential direction of the tyre.

Advantageously, the crown reinforcement comprises a working reinforcement comprising at least one cord as defined above.

Advantageously, the working reinforcement comprises at least one working ply comprising filamentary metal working reinforcing elements arranged substantially parallel to one another, each filamentary metal working reinforcing element making an angle at most equal to 60°, preferably ranging from 15° to 40° with the circumferential direction of the tyre and being formed by a cord as defined above.

In one advantageous embodiment, the working reinforcement comprises at least first and second working plies, each first and second working ply respectively comprising first and second filamentary metal working reinforcing elements arranged substantially parallel to one another in each first and second working ply, each first and second filamentary metal working reinforcing element making an angle at most equal to 60°, preferably ranging from 15° to 40° with the circumferential direction of the tyre and being formed by a cord as defined above.

Advantageously, the crown reinforcement comprises a protective reinforcement comprising at least one protective ply comprising filamentary metal protective reinforcing elements arranged substantially parallel to one another, each filamentary metal protective reinforcing element making an angle at least equal to 10°, preferably ranging from 10° to 35° and preferentially from 15° to 30° with the circumferential direction of the tyre.

In one advantageous embodiment, the protective reinforcement comprises first and second protective plies, each first and second protective ply respectively comprising first and second filamentary metal protective reinforcing elements arranged substantially parallel to one another in each first and second protective ply, each first and second filamentary metal protective reinforcing element making an angle at least equal to 10°, preferably ranging from 10° to 35° and preferentially from 15° to 30° with the circumferential direction of the tyre.

In a preferred embodiment, the protective reinforcement is interposed radially between the tread and the working reinforcement.

Advantageously, the crown reinforcement comprises an additional reinforcement comprising at least one additional ply comprising additional filamentary metal reinforcing elements arranged substantially parallel to one another in the additional ply, each additional filamentary metal reinforcing element making an angle at most equal to 10°, preferably ranging from 5° to 10° with the circumferential direction of the tyre.

In one advantageous embodiment, the additional reinforcement comprises first and second additional plies, each first and second additional ply respectively comprising first and second additional filamentary metal reinforcing elements arranged substantially parallel to one another in each first and second additional ply, each first and second additional filamentary metal reinforcing element making an angle at most equal to 10°, preferably ranging from 5° to 10° with the circumferential direction of the tyre.

The invention will be better understood on reading the following description, given solely by way of non-limiting example and with reference to the drawings.

Example of a Tyre According to the Invention

A frame of reference X, Y, Z corresponding to the usual respectively axial (X), radial (Y) and circumferential (Z) orientations of a tyre has been depicted in the figures.

The “median circumferential plane” M of the tyre is the plane which is normal to the axis of rotation of the tyre and which is situated equidistant from the annular reinforcing structures of each bead, and passes through the middle of the crown reinforcement.

FIGS. 1 and 2 depict a tyre according to the invention and denoted by the general reference 10.

The tyre 10 is for a heavy vehicle of construction plant type, for example of “dumper” type. Thus, the tyre 10 has a dimension of the type 53/80R63.

The tyre 10 has a crown 12 reinforced by a crown reinforcement 14, two sidewalls 16 and two beads 18, each of these beads 18 being reinforced with an annular structure, in this instance a bead wire 20. The crown reinforcement 14 is surmounted radially by a tread 22 and connected to the beads 18 by the sidewalls 16. A carcass reinforcement 24 is anchored in the two beads 18 and is in this instance wound around the two bead wires 20 and comprises a turnup 26 positioned towards the outside of the tyre 20, which is shown here fitted onto a wheel rim 28. The carcass reinforcement 24 is surmounted radially by the crown reinforcement 14.

The carcass reinforcement 24 comprises at least one carcass ply 30 comprising filamentary metal carcass reinforcing elements 31 arranged substantially parallel to one another in the carcass ply 30 and extending from one bead 18 to the other so as to form an angle of between 80° and 90° with the circumferential direction Z of the tyre 10.

The tyre 10 also comprises a sealing ply 32 made up of an elastomer (commonly known as “inner liner”) which defines the radially internal face 34 of the tyre 10 and which is intended to protect the carcass ply 30 from the diffusion of air coming from the space inside the tyre 10.

The crown reinforcement 14 comprises, radially from the outside towards the inside of the tyre 10, a protective reinforcement 36 arranged radially on the inside of the tread 22, a working reinforcement 38 arranged radially on the inside of the protective reinforcement 36 and an additional reinforcement 50 arranged radially on the inside of the working reinforcement 38. The protective reinforcement 36 is thus interposed radially between the tread 22 and the working reinforcement 38. The working reinforcement 38 is interposed radially between the protective reinforcement 36 and the additional reinforcement 50.

The protective reinforcement 36 comprises first and second protective plies 42, 44, the first ply 42 being arranged radially on the inside of the second ply 44. Each first and second protective ply 42, 44 respectively comprises first and second filamentary metal protective reinforcing elements 43, 45 arranged substantially parallel to one another in each first and second protective ply 42, 44. Each first and second filamentary metal protective reinforcing element 43, 45 makes an angle at least equal to 10°, preferably ranging from 10° to 35° and preferentially from 15° to 30°, with the circumferential direction Z of the tyre.

The working reinforcement 38 comprises first and second working plies 46, 48, the first ply 46 being arranged radially on the inside of the second ply 48. Each ply 46, 48 comprises at least one cord 60. Each first and second working ply 46, 48 respectively comprises first and second filamentary metal working reinforcing elements 47, 49 arranged substantially parallel to one another in each first and second working ply 46, 48. Each first and second filamentary metal working reinforcing element 47, 49 is formed here by a cord 60 described hereinafter. Each first and second filamentary metal working reinforcing element 47, 49 makes an angle at most equal to 60°, preferably ranging from 15° to 40°, with the circumferential direction Z of the tyre 10. Optionally, the first and second filamentary metal working reinforcing elements 47, 49 are crossed from one working ply to the other.

The additional reinforcement 50, also referred to as the limiting block, the function of which is to partially react the mechanical stresses of inflation, comprises first and second additional plies 52, 54, each first and second additional ply 52, 54 respectively comprising first and second additional filamentary metal reinforcing elements 53, 55 arranged substantially parallel to one another in each first and second additional ply 52, 54. Each first and second additional filamentary metal reinforcing element 53, 55 makes an angle at most equal to 10°, preferably ranging from 5° to 10°, with the circumferential direction Z of the tyre 10. The additional filamentary metal reinforcing elements are, for example, as described in FR 2 419 181 or FR 2 419 182.

Cord According to a First Embodiment of the Invention

FIG. 3 depicts the cord 60 according to embodiment A with a very low modulus according to a first embodiment of the invention.

The cord 60 is metal and of the multi-strand type with two cylindrical layers. Thus, it will be understood that there are two layers, not more, not less, of strands of which the cord 60 is made. The layers of strands are adjacent and concentric. The cord 60 is devoid of polymer compound and of elastomer compound when it is not integrated into the tyre.

The cord 60 comprises an internal layer CI of the cord 60, and an external layer CE of the cord 60. The internal layer CI is made up of J>1 internal strands TI, namely of several internal strands TI, wound in a helix. The external layer CE is made up of L>1 external strands, namely of several external strands TE wound in a helix around the internal layer CI. In this instance, J=2, 3 or 4, preferably J=3 or 4. In addition, L=7, 8, 9 or 10, preferably L=8, 9 or 10. With J=3, L=7, 8 or 9 and in this instance and here J=3, L=8.

The cord 60 also comprises a wrapper F made up of a single wrapping wire.

The internal layer CI is wound in a helix in a direction of winding of the internal layer of the cord, here the direction S. The internal strands TI are wound in a helix with a pitch PI such that 10 mm≤PI≤65 mm and preferably 10 mm≤PI≤45 mm. Here, PI=15 mm. The helix angle α of each internal strand TI in the internal layer CI of the cord 60 according to embodiment A ranges from 3° to 42° and in this instance α=19.8°.

The external layer CE is wound in a helix around the internal layer CI in a direction of winding of the external layer of the cord that is the opposite of the direction of winding of the internal layer of the cord, here the direction Z. The external strands TE are wound in a helix around the internal strand TI with a pitch PE such that 30 mm≤PE≤65 mm and preferably 30 mm≤PE≤60 mm. Here, PE=40 mm. The helix angle α′ of each external strand TE in the external layer CE of the cord 60 ranges from 7° to 38° and, in the case of the cord 60 according to embodiment A, from 13° to 38° and in this instance α′=20.0°.

The wrapper F is wound around the external layer CE in a direction of winding of the wrapper, here the opposite to the direction of winding of the external layer CE, in this instance in the S-direction. The wrapping wire is wound in a helix around the external strands TE with a pitch PF such that 2 mm≤PF≤10 mm and preferably, 3 mm≤PF≤8 mm. Here, PF=5.1 mm.

The assembly made up of the internal CI and external CE layers, which means to say the cord 60 without the wrapper F, has a diameter D greater than or equal to 4 mm, preferably greater than or equal to 4.5 mm, and less than or equal to 7 mm, preferably less than or equal to 6.5 mm. Here, D=6.1 mm.

The internal layer CI of internal strands TI has a diameter DI. Each external strand TE has a diameter DE. In this instance, DI=3.18 mm, DE=1.46 mm.

The external layer CE of the cord 60 is desaturated and completely unsaturated. The mean inter-strand distance E separating two adjacent external strands TE is thus greater than or equal to 30 μm. Preferably, the mean inter-strand distance E separating two adjacent external strands TE is greater than or equal to 70 μm more preferentially greater than or equal to 100 μm, even more preferentially greater than or equal to 150 μm and very preferentially greater than or equal to 200 μm. Here, E=241 μm. The sum SIE of the inter-thread distances E of the external layer CE is greater than the diameter DE of the external strands of the external layer CE. Here, the sum SIE=8×0.241=1.93 mm, which is a value strictly greater than DE=1.46 mm.

Internal Strands TI of the Cord 60

Each internal strand TI has two layers. Each internal strand TI comprises, here is made up of, two layers, not more, not less.

Each internal strand TI comprises an internal layer C1 made up of Q≥1 internal threads F1 and an external layer C2 made up of N>1 external threads F2 wound in a helix around and in contact with the internal layer C1.

Q=2, 3 or 4, preferably Q=3 or 4. N=7, 8, 9 or 10, preferably N=8, 9 or 10. Where Q=3, N=7, 8 or 9 and in this instance Q=3, N=8.

The internal layer C1 of each internal strand TI is wound in a helix in a direction of winding of the internal layer C1 of the internal strand TI that is identical to the direction of winding of the internal layer CI of the cord, here in the S-direction. The Q internal threads F1 are assembled within each internal strand TI at a pitch p1 such that 2 mm≤p1≤20 mm. Here p1=3 mm. The helix angle β of each internal thread F1 in the internal layer C1 within each internal strand TI ranges from 4° to 25°, here β=23.4°.

The external layer C2 of each internal strand TI is wound around and in contact with the internal layer C1 in a direction of winding of the external layer C2 of the internal strand TI that is identical to the direction of winding of the internal layer CI of the cord, here in the S-direction. The N external threads F2 are wound in a helix around the Q internal threads F1 and are assembled within each internal strand TI at a pitch p2 such that 4 mm≤p2≤40 mm. Here, p2=6 mm. The helix angle γ of each external thread F2 in the external layer C2 within each internal strand TI ranges from 6° to 31°, here γ=30.2°.

11°≤2α+β+γ≤110° and because Q>1, 16°≤2α+β+γ≤110°. In the embodiment of the cord 60 according to embodiment A where Q>1, 23°≤2α+β+γ≤110°. In this instance, 2α+β+γ=93.2°.

Each internal thread F1 and external thread F2 of each internal strand TI has, respectively, a diameter D1, D2. Each diameter of the internal threads D1 and of the external threads D2 of each internal strand TI ranges from 0.15 mm to 0.60 mm, preferably from 0.20 mm to 0.50 mm, more preferably from 0.23 mm to 0.45 mm and more preferably still from 0.25 mm to 0.40 mm. Each internal thread F1 of each internal strand TI has a diameter D1 greater than or equal to, in this instance equal to, the diameter D2 of each external thread F2 of each internal strand TI. In this particular instance, D1=D2=0.35 mm.

Because of the relatively short pitch p2, the external layer C2 of each internal strand TI is desaturated and incompletely unsaturated. The inter-thread distance I2 of the external layer C2 on average separating the N external threads is greater than or equal to 5 μm. The inter-thread distance I2 is preferably greater than or equal to 15 μm and in this instance is equal to 29 μm. The sum SI2 of the inter-thread distances I2 of the external layer C2 is greater than the diameter d2 of the external threads F2 of the external layer C2. In this instance, the sum SI2=8×0.029=0.23 mm, which is a value strictly less than D2=0.35 mm.

From the values described hereinabove, it is possible to calculate the indicator MI=200×cos⁴(α)×[Q×(D1/2)²×cos⁴(β)+N×(D2/2)²×cos⁴(γ)]/ [Q×(D1/2)²+N×(D2/2)²] where D1 and D2 are expressed in mm, α, β and γ are expressed in degrees and as defined hereinabove.

35≤MI≤195 and, in the embodiment of the cord 60 according to embodiment A, 62≤MI≤192. Here, the internal layer having a relatively low modulus, 35≤MI≤135 and in the embodiment of the cord 60 according to embodiment A, 62≤MI≤135. In this particular instance, MI=94.

Also, 25 GPa≤EI≤180 GPa and, in the embodiment of the cord 60 according to embodiment A, 25 GPa≤EI≤180 GPa. Here, the internal layer has a relatively low modulus, 25 GPa≤EI≤94 GPa, and in the embodiment of the cord 60 according to embodiment A, 27 GPa≤EI≤94 GPa. In this particular instance, EI=53 GPa.

External Strands TE of the Cord 60

Each external strand TE has two layers. Thus, each external strand TE comprises, here is made up of, two layers, not more, not less.

Each external strand TE comprises an internal layer C1′ made up of Q′≥1 internal threads F1′ and an external layer C2′ made up of N′>1 external threads F2′ wound in a helix around and in contact with the internal layer C1′.

Q′=2, 3 or 4, preferably Q′=3 or 4. N′=7, 8, 9 or 10, preferably N′=8, 9 or 10. Where Q′=3, N′=7, 8 or 9 and in this instance Q′=3, N′=8.

The internal layer C1′ of each external strand TE is wound in a helix in a direction of winding of the internal layer C1′ of the external strand TE that is identical to the direction of winding of the external layer CE of the cord, here in the Z-direction. The Q′ internal threads F1′ are assembled within each external strand TE at a pitch p1′ such that 2 mm≤p1′≤20 mm, preferably 5 mm≤p1′≤20 mm. Here p1′=10 mm. The helix angle β′ of each internal thread F1′ in the internal layer C1′ within each external strand TE ranges from 4° to 25°, preferably from 4° to 17°, here β′=7.3°.

The external layer C2′ of each external strand TE is wound around and in contact with the internal layer C1′ in a direction of winding of the external layer C2′ of the external strand TE that is identical to the direction of winding of the external layer CE of the cord, here in the Z-direction. The N′ external threads F2′ are wound in a helix around the Q′ internal threads F1′ and are assembled within each external strand TE at a pitch p2′ such that 4 mm≤p2′≤40 mm. Here, p2′=20 mm. The helix angle γ′ of each external thread F2′ in the external layer C2′ within each external strand TE ranges from 5° to 31°, here γ′=9.8°.

23°≤2α′+β′+γ′≤97° and because Q′>1, 28°≤2α′+β′+γ′≤97° and, in the embodiment of the cord 60 according to embodiment A, 43°≤2α′+β′+γ′≤97°. In this particular instance, 2α′+β′+γ′=57.1°.

Each internal F1′ and external F2′ thread of each external strand TE respectively has a diameter D1′, D2′. Each diameter of the internal D1′ and external threads D2′ of each external strand TE ranges from 0.15 mm to 0.60 mm, preferably from 0.20 mm to 0.50 mm, more preferentially from 0.23 mm to 0.45 mm and more preferentially still from 0.25 mm to 0.40 mm. Each Q′ internal thread F1′ of each external strand TI′ has a diameter D1′ greater than or equal to, in this instance equal to the diameter D2′ of each external thread F2′ of each external strand TE. In this instance, D1′=D2′=0.35 mm.

The external layer C2′ of each external strand TE is desaturated and incompletely unsaturated. The inter-thread distance I2′ of the external layer C2′ on average separating the N′ external threads is greater than or equal to 5 μm. The inter-thread distance I2′ is preferably greater than or equal to 15 μm, more preferentially greater than or equal to 35 μm, even more preferentially greater than or equal to 50 μm and very preferentially greater than or equal to 60 μm and in this instance equal to 69 μm. The sum SI2′ of the inter-thread distances I2′ of the external layer C2′ is greater than the diameter D2 of the external threads F2′ of the external layer C2′. In this instance, the sum SI2′=8×0.069=0.55 mm, which is a value strictly greater than D2′=0.35 mm.

From the values described hereinabove, it is possible to calculate ME=200×cos⁴(α′)×[Q′×(D1′/2)²×cos⁴(β′)+N′×(D2′/2)²×cos⁴(γ)]/[Q′×(D1′/2)²+N′×(D2′/2)²] where D1 and D2 are expressed in mm, α′, β′ and γ′ are expressed in degrees and as defined hereinabove.

75≤ME≤188 and, in the embodiment of the cord 60 according to embodiment A, 75≤ME≤171. Here, the internal layer having a relatively high modulus, 121≤ME≤188 and in the embodiment of the cord 60 according to embodiment A, 121≤ME≤171. In this particular instance, ME=148.

Each thread F1, F2, F1′, F2′ has a breaking strength, denoted Rm, such that 2500≤Rm≤3100 MPa. The steel for these threads is said to be of SHT (“Super High Tensile”) grade. Other threads may be used, for example threads of an inferior grade, for example of NT (“Normal Tensile”) or HT (“High Tensile”) grade, just as may threads of a superior grade, for example of UT (“Ultra Tensile”) or MT (“Mega Tensile”) grade.

51°≤2α+β+γ+2α′+β′+γ′≤184° and because Q>1 and Q′>1, 68°≤2α+β+γ+2α′+β′+γ′≤184°. In the embodiment of the cord 60 according to embodiment A, 85°≤2α+β+γ+2α′+β′+γ′≤184° and because Q>1 and Q′>1, 110°≤2α+β+γ+2α′+β′+γ′≤184°. In this particular instance 2α+β+γ+2α′+β′+γ′=150.3°.

1.31≤ME/MI, preferably 1.31≤ME/MI≤3.30 and, in the case of the cord 60 according to embodiment A, 1.31≤ME/MI≤2.52 and in this instance ME/MI=1.58. 1.21≤EC/EI, preferably 1.21≤EC/EI≤3.00 and, in the case of the cord 60 according to embodiment A, 1.24≤EC/EI≤3.00 and in this instance EC/EI=1.62.

According to the invention, the indicator MC=(J×MI+L×ME)/(J+L) is such that 100≤MC≤175 and preferably 100≤MC≤170. In the embodiment of the cord 60 according to embodiment A, 100≤MC≤156. In this particular instance, MC=133.

We also have 50 GPa≤EC≤160 GPa and in the embodiment of the cord 60 according to embodiment A, 50 GPa≤EC≤89 GPa. In this instance EC=86 GPa which makes the cord 60 a very low-modulus cord.

Method for Manufacturing the Cord According to the Invention

The cord according to the invention is manufactured using a method comprising steps well known to those skilled in the art.

In a step for manufacturing the internal strands using the following steps, preferably carried out in line and continuously:

-   first of all, a first step of assembling, by twisting, the Q     internal threads F1 of the internal layer C1 at the pitch p1 and in     the S-direction to form the internal layer C1 at a first assembling     point; -   followed by a second step of assembling, by twisting, the N external     threads F2 around the N internal threads F1 of the internal layer C1     at the pitch p2 and in the S-direction to form the external layer C2     and each internal strand TI at a second assembling point; -   preferably a final twist-balancing step.

In a step for manufacturing the external strands using the following steps, preferably carried out in line and continuously:

-   first of all, a first step of assembling, by twisting, the Q′     internal threads F1′ of the internal layer C1′ at the pitch p1′ and     in the Z-direction to form the internal layer C1′ at a first     assembling point; -   followed by a second step of assembling, by twisting, the N′     external threads F2′ around the N′ internal threads F1′ of the     internal layer C1′ at the pitch p2′ and in the Z-direction to form     the external layer C2′ and each external strand TE at a second     assembling point; -   preferably a final twist-balancing step.

What is meant here by “twist balancing” is, as is well known to those skilled in the art, the cancellation of the residual twist torques (or the elastic return of the twist) applied to each thread of the strand, in the intermediate layer as in the external layer.

After this final twist-balancing step, the manufacture of each strand is complete. Each strand is wound onto one or more receiving reels, for storage, prior to the later operation of assembling the elementary strands in order to obtain the multi-strand cord.

In order to manufacture the multi-strand cord of the invention, the method, as is well known to those skilled in the art, is to cable together the strands previously obtained, using cabling machines rated for assembling strands.

In a step of manufacturing the internal layer CI, the Q internal strands TI are assembled by cabling at the pitch PI and in the S-direction to form the internal layer CI at a first assembling point. In the embodiments in which the pitch PI is relatively short and therefore in which α is relatively high, the Q internal strands TI are assembled by twisting in order to limit the risk of instability of the internal layer CI of the strands TI.

Then, in a later manufacturing step, the L external strands TE are assembled by cabling around the internal layer CI at the pitch PE and in the Z-direction to form the assembly of the layers CI and CE. In the embodiments in which the pitch PE is relatively short and therefore in which α′ is relatively high, the L external stands TE are assembled by twisting in order to limit the risk of instability of the external layer CE of the strands TE.

In a second manufacturing step, the wrapper F is wound, at the pitch PF and in the S-direction, around the assembly previously obtained.

The tyre 10 is obtained by a method involving a step of embedding cords 60 in a polymer matrix of a polymer composition, in this instance an elastomer composition such as, for example, described hereinbelow. Each cord 60 is, prior to the embedding step, rid of any polymer or elastomer composition individually covering one or more, or collectively covering several, internal strands TI of the internal layer CI of the cord 60.

The cord is then incorporated by skimming into composite fabrics formed from a known composition based on natural rubber and carbon black as reinforcing filler, conventionally used for manufacturing crown reinforcements of radial tyres. This compound essentially contains, in addition to the elastomer and the reinforcing filler (carbon black), an antioxidant, stearic acid, an extender oil, cobalt naphthenate as adhesion promoter, and finally a vulcanization system (sulfur, accelerator and ZnO).

The composite fabrics reinforced by these cords have an elastomer compound matrix formed from two thin layers of elastomer compound which are superposed on either side of the cords and which have a thickness of between 1 and 4 mm inclusive, respectively. The skim-coating pitch (the pitch at which the cords are laid in the elastomer compound fabric) ranges from 4 mm to 8 mm.

These composite fabrics are then used as working ply in the crown reinforcement during the method of manufacturing the tyre, the steps of which are otherwise known to a person skilled in the art.

Cord According to a Second Embodiment of the Invention

A low-modulus cord 61 according to embodiment B according to a second embodiment of the invention will be described. Elements similar to the first embodiment are denoted by identical references.

Amongst the differences between the cords 60 and 61, it will be noted that cord 61 according to embodiment B is such that the helix angle α ranges from 3° to 36° and in this instance α=10° and that the helix angle α′ ranges from 9° to 27° and in this instance α′=16.1°.

It will also be noted, in the case of the cord 61 according to embodiment B, 13°≤2α+β+γ≤110° and because Q>1, 16°≤2α+β+γ≤110°. In this particular instance, 2α+β+γ=46.2°.

It will be noted that, in the case of the cord 61 according to embodiment B, 75≤MI≤195. Here, the internal layer having a relatively high modulus, 136≤MI≤195. In this particular instance, MI=164. It will also be noted that, in the embodiment of the cord 61, the internal layer having a relatively high modulus, 95 GPa≤EI≤180 GPa. In this particular instance, EI=148 GPa.

It will also be noted that, in the case of the cord 61 according to embodiment B, 31°≤2α′+β′+γ′≤71° and because Q′>1, 39°≤2α′+β′+γ′≤71°. In this particular instance, 2α′+β′+γ′=54.3°.

It will be noted that, in the case of the cord 61 according to embodiment B, 115≤ME≤178 and, in the embodiment of the cord 61 according to embodiment B having a relatively high modulus, 121≤ME≤178. In this particular instance, ME=156.

It will also be noted that, in the case of the cord 61 according to embodiment B, 65°≤2α+β+γ+2α′+β′+γ′≤153° and because Q>1 and Q′>1, 79°≤2α+β+γ+2α′+β′+γ′≤153°. In this particular instance 2α+β+γ+2α′+β′+γ′=100.5°.

It will be noted that 0.70≤ME/MI≤1.30 and in this instance ME/MI=0.95. It will be noted that 0.57≤EC/EI≤1.43 and, in the case of the cord 61 according to embodiment B, 0.58≤EC/EI≤1.29 and in this instance EC/EI=0.86.

According to the invention, the indicator MC=(J×MI+L×ME)/(J+L) is such that 100≤MC≤175 and preferably 100≤MC≤170. It will also be noted that, in the embodiment of the cord 61 according to embodiment B, 130≤MC≤172. In this particular instance, MC=158. It will be noted that, in the embodiment of the cord 61 according to embodiment B, 90 GPa≤EC≤130 GPa which makes the cord 61 a low-modulus cord. Here, EC=127 GPa.

Cord According to a Third Embodiment of the Invention

FIG. 4 shows a medium-modulus cord 62 according to embodiment C according to a third embodiment of the invention. Elements similar to those of the cords already described are denoted by identical references.

Amongst the differences between the cords 60 and 62, it will be noted that the helix angle α of each internal strand TI in the internal layer CI of the cord 62 according to embodiment C ranges from 3° to 24° and in this particular instance α=9.1°. It will also be noted that the helix angle α′ of each external strand TE in the external layer CE of the cord 62 according to embodiment C ranges from 7° to 22° and in this particular instance α′=16.2°.

It will also be noted that, in the case of the cord 62 according to embodiment C, 11°≤2α+β+γ≤64° and because Q>1, 16°≤2α+β+γ≤63° and in this particular instance, 2α+β+γ=29.6°.

It will be noted that, in the embodiment of the cord 62 according to embodiment C, 120≤MI≤195. Here, the internal layer having a relatively high modulus, 136≤MI≤195 and in this particular instance, MI=186. It will also be noted that, in the embodiment of the cord 62 according to embodiment C, 78 GPa≤EI≤180 GPa. Here, the internal layer has a relatively high modulus, 95 GPa≤EI≤180 GPa, and in this particular instance, EI=173 GPa.

It will also be noted that, in the embodiment of the cord 62 according to embodiment C, 23°≤2α′+β′+γ′≤58° and because Q′>1, 27°≤2α′+β′+γ′≤58°. In this particular instance, 2α′+β′+γ′=49.5°.

It will be noted that, in the embodiment of the cord 62 according to embodiment C, 144≤ME≤188. In this particular instance, ME=162.

It will be noted that, in the embodiment of the cord 62 according to embodiment C, 45°≤2α+β+γ+2α′+β′+γ′≤108° and because Q>1 and Q′>1, 60°≤2α+β+γ+2α′+β′+γ′≤108°. In this particular instance 2α+β+γ+2α′+β′+γ′=79.1°.

It will be noted that 0.70≤ME/MI≤1.30 and, in the embodiment of the cord 62 according to embodiment C, 0.76≤ME/MI≤1.30 and in this instance ME/MI=0.87. It will also be noted that 0.57≤EC/EI≤1.43 and, in the embodiment of the cord 62 according to embodiment C, 0.72≤EC/EI≤1.43 and in this instance EC/EI=0.86.

According to the invention, the indicator MC=(J×MI+L×ME)/(J+L) is such that 100≤MC≤175 and preferably 100≤MC≤170. It will be noted that, in the embodiment of the cord 62 according to embodiment C, 150≤MC≤175. In this particular instance, MC=169.

It will be noted that, in the embodiment of the cord 62 according to embodiment C, 131 GPa≤EC≤160 GPa which makes the cord 62 a medium-modulus cord. Here, EC=149 GPa.

Cord According to a Fourth Embodiment of the Invention

A very low-modulus cord 63 according to embodiment A according to a fourth embodiment of the invention will now be described. Elements similar to those of the cords already described are denoted by identical references.

Amongst the differences between the cords 60 and 63, it will be noted that, the internal layer having a relatively high modulus, 136≤MI≤195 and in the embodiment of the cord 63 according to embodiment A, 136≤MI≤192. In this particular instance, MI=173. It will be noted that, the internal layer has a relatively high modulus, 95 GPa≤EI≤180 GPa. In this particular instance, EI=158 GPa.

It will also be noted that, the external layer having a relatively low modulus, 75≤ME≤120. In this particular instance, ME=105.

It will be noted that, in the embodiment of the cord 63, ME/MI≤0.69, preferably 0.39≤ME/MI≤0.69 and in this instance ME/MI=0.61. It will also be noted that EC/EI≤0.65, preferably 0.36≤EC/EI≤0.65 and, in the case of the cord 63 according to embodiment A, 0.36≤EC/EI≤0.56 and in this instance EC/EI=0.50.

Cord According to a Fifth Embodiment of the Invention

A very low-modulus cord 64 according to embodiment A according to a fifth embodiment of the invention will now be described. Elements similar to those of the cords already described are denoted by identical references.

Amongst the differences between the cords 60 and 64, it will be noted in particular that 0.70≤ME/MI≤1.30 and here ME/MI=1.17. It will also be noted that 0.57≤EC/EI≤1.43 and, in the embodiment of the cord 64 according to embodiment A, 0.57≤EC/EI≤1.23 and here EC/EI=1.08.

Cord According to a Sixth Embodiment of the Invention

A low-modulus cord 65 according to embodiment B according to a sixth embodiment of the invention will now be described. Elements similar to those of the cords already described are denoted by identical references.

Amongst the differences between the cords 61 and 65, it will be noted that, the internal layer having a relatively low modulus, 75≤MI≤135 and in this instance MI=98. It will also be noted that, the internal layer has a relatively low modulus, 25 GPa≤EI≤94 GPa and in this instance EI=59 GPa.

It will also be noted that, in the embodiment of the cord 65, 1.31≤ME/MI, preferably 1.31≤ME/MI≤3.30 and, in the embodiment of the cord 65 according to embodiment B, 1.31≤ME/MI≤2.35 and in this instance ME/MI=1.65. It will also be noted that, in the embodiment of the cord 65, 1.21≤EC/EI≤3.00 and, in the embodiment of the cord 65 according to embodiment B, 1.21≤EC/EI≤2.82 and in this instance EC/EI=1.63.

Cord According to a Seventh Embodiment of the Invention

A medium-modulus cord 66 according to embodiment C according to a seventh embodiment of the invention will now be described. Elements similar to those of the cords already described are denoted by identical references.

Amongst the differences between the cords 62 and 66, it will be noted that the cord 66 is such that J=4 and L=10 and that each thread F1, F1′, F2, F2′ is such that its diameter D1, D1′, D2, D2′ ranges from 0.25 mm to 0.40 mm and here D1=D1′=D2=D2′=0.35 mm.

It will be noted that each cord described above is metal and of the multi-strand type with two cylindrical layers. Thus, it will be understood that there are two layers, not more, not less, of strands of which the cord is made. The layers of strands are adjacent and concentric. It will also be noted that the cord is devoid of polymer compound and of elastomer compound when it is not integrated into the tyre.

Table 1 below summarizes the features of the cords 60 to 66 described hereinabove and those of example 2-2 of WO2008026271 which is identified by the letter T2-2 in Table 1.

This Table 1 lists the measured modulus values EC of the cords. The force-elongation curves measured in accordance with standard ASTM D2969-04 of 2014 of the cords 60, 61 and 62 according to the invention are illustrated in FIGS. 4, 5 and 7, respectively. In each of these figures, the tangent to the elastic part of the force-elongation curve has been drawn using a continuous line making it possible to calculate the EC modulus values. Also, the structural elongations As, elastic elongations Ae, and plastic elongations Ap have been identified. The structural elongation As is measured between the origin and the intersection of the tangent to the elastic part with the abscissa axis. The elastic elongation Ae is measured between the intersection of the tangent to the elastic part with the abscissa axis and the intersection of the tangent to the elastic part with the ordinate value corresponding to the elongation at break. The plastic elongation Ap is measured between the intersection of the tangent to the elastic part with the ordinate value corresponding to the elongation at break, and the elongation at break.

Of course, the invention is not restricted to the exemplary embodiments described above.

For reasons of industrial feasibility, of cost and of overall performance, it is preferable to implement the invention with linear threads, that is to say straight threads. In other words, the threads used are not pre-formed prior to being assembled.

It will also be possible to combine the features of the various embodiments described or envisaged above, with the proviso that these features are compatible with one another.

TABLE 1 Cord T2-2 60 61 62 63 64 65 66 TI Q/N 3/9 3/8 3/8 3/8 3/8 3/8 3/8 3/8 D1/D2 0.255/0.255 0.35/0.35 0.35/0.35 0.26/0.26 0.35/0.35 0.40/0.40 0.26/0.26 0.35/0.35 PI/p1/p2 (mm) 55/8/16 15/3/6 30/7.4/11.8 30/11.2/22.2 30/10/20 40/3.4/6.9 15/2.2/4.5 30/15/30 α/β/γ 4/6.6/9 19.8/23.4/30.2 10/9.8/16.4 9.1/4.8/6.6 12.3/7.3/9.8 10.6/23.6/30.1 18.3/23.7/30 12.3/4.8/6.6 2α + β + γ 23.6 93.2 46.2 29.6 41.7 74.9 90.3 36 MI 194 94 164 186 173 112 98 178 EI (GPa) >170 53 148 173 158 76 59 164 TE Q′/N′ 3/9 3/8 3/8 3/8 3/8 3/8 3/8 3/8 D1′/D2′ 0.255/0.255 0.35/0.35 0.35/0.35 0.26/0.26 0.35/0.35 0.40/0.40 0.26/0.26 0.35/0.35 PE/p1′/p2′ (mm) 60/8/16 40/10/20 50/7.7/15.4 40/10/20 60/3/6 40/10/20 40/10/20 50/10/20 α′/β′/γ′ 9.9/6.6/9 20/7.3/9.8 16.1/9.4/12.7 16.2/7.3/9.8 14.7/23.4/30.2 24.2/7.3/9.8 16.4/7.3/9.8 17.4/7.3/9.8 2α′ + β′ + γ′ 35.4 57.1 54.3 49.5 83 65.5 49.9 51.9 ME 180 148 156 162 105 131 161 157 J/L 3/9 3/8 3/8 4/9 4/9 4/9 4/10 4/10 MC 184 133 158 169 126 125 143 163 ME/MI 0.94 1.58 0.95 0.87 0.61 1.17 1.65 0.88 2α + β + γ + 2α′ + β′ + γ′ 59 150.3 100.5 79.1 124.7 140.4 140.2 87.9 EC (GPa) >160 86 127 149 79 82 96 143 EC/EI / 1.62 0.86 0.86 0.50 1.08 1.63 0.87 

The invention claimed is:
 1. A two-layer multi-strand cord comprising: an internal layer of the cord made up of J>1 internal strands wound in a helix, each internal strand having two layers and comprising an internal layer made up of Q≥1 internal threads of diameter D1, and an external layer made up of N>1 external threads of diameter D2 wound around the internal layer; and an external layer of the cord made up of L>1 external strands wound around the internal layer of the cord, each external strand having two layers and comprising an internal layer made up of Q′≥1 internal threads of diameter D1′, and an external layer made up of N′>1 external threads of diameter D2′ wound around the internal layer, wherein the cord satisfies the following relationship: 100≤MC≤175 where MC=(J×MI+L×ME)/(J+L), where MI=200×cos⁴(α)×[Q×(D1/2)²×cos⁴(β)+N×(D2/2)²×cos⁴(γ)]/[Q×(D1/2)²+N×(D2/2)²], where D1 and D2 are expressed in mm, α is the helix angle of each internal strand in the internal layer of the cord, β is the helix angle of each internal thread in the internal layer within each internal strand, and γ is the helix angle of each external thread in the external layer within each internal strand, where ME=200×cos⁴(α′)×[Q′×(D1′/2)²×cos⁴(β′)+N′×(D2′/2)²×cos⁴(γ′)]/[Q′×(D1′/2)²+N′×(D2′/2)²], and where D1′ and D2′ are expressed in mm, α′ is the helix angle of each external strand in the external layer of the cord, β′ is the helix angle of each internal thread in the internal layer within each external strand, and γ′ is the helix angle of each external thread in the external layer within each external strand.
 2. The two-layer multi-strand cord according to claim 1, wherein 100≤MC≤170.
 3. The two-layer multi-strand cord according to claim 1, wherein 35≤MI≤195.
 4. The two-layer multi-strand cord according to claim 1, wherein 75≤ME≤188.
 5. The two-layer multi-strand cord according to claim 1, wherein 0.70≤ME/MI≤1.30.
 6. The two-layer multi-strand cord according to claim 1, wherein the helix angle α of each internal strand in the internal layer of the cord ranges from 3° to 42°.
 7. The two-layer multi-strand cord according to claim 1, wherein the helix angle α′ of each external strand in the external layer of the cord ranges from 7° to 38°.
 8. The two-layer multi-strand cord according to claim 1, wherein 11°≤2α+β+γ≤110°.
 9. The two-layer multi-strand cord according to claim 1, wherein 23°≤2α′+β′+γ′≤97°.
 10. The two-layer multi-strand cord according to claim 1, wherein 51°≤2α+β+γ+2α′+β′+γ′≤184°.
 11. The two-layer multi-strand cord according to claim 1, wherein J=2, 3 or
 4. 12. The two-layer multi-strand cord according to claim 1, wherein L=7, 8, 9 or
 10. 13. The two-layer multi-strand cord according to claim 1, wherein the external layer of the cord is desaturated.
 14. The two-layer multi-strand cord according to claim 1, wherein the cord has a modulus EC such that 50 GPa≤EC≤160 GPa.
 15. A tire comprising the two-layer multi-strand cord according to claim
 1. 